Process for preparing 1,1,1-trifluoro-2,2-dichloroethane by hydrofluorination in the presence of catalysts

ABSTRACT

A process for preparing 1,1,1-trifluoro-2,2-dichloroethane by hydrofluorination,in the gas phase, of perchloroethylene in the presence of a catalyst comprising chrome oxides supported on AlF 3  in the gamma and/or beta form.

This is a division of co-pending application Ser. No. 07/981,651 filedNov. 25, 1992 now U.S. Pat. No. 5,276,224 , which is a division of Ser.No. 07/793,879 filed Nov. 18, 1991 now U.S. Pat. No. 5,262,524, which isa continuation of Ser. No. 07/584,960, filed Sep. 19, 1990, now U.S.Pat. No. 5,091,601, which is a continuation of Ser. No. 07/403.070,filed Sep. 5, 1989, now U.S. Pat. No. 4,967,023, which is a continuationof Ser. No. 07/163,659, filed on Mar. 3, 1988, now abandoned.

FIELD OF THE INVENTION

This invention relates to a process for preparing1,1,1-trifluoro-2,2-dichloroethane by hydrofluorination, in the gasphase, of perchloroethylene in the presence of a catalyst comprising Cr₂O₃ supported on AlF₃.

BACKGROUND OF THE INVENTION

Well known is the requirement of having available industrial processesfor preparing 1,1,1-trifluoro-2,2-dichloroethane with good yields.

It is well known how to prepare 1,1,1-trifluoro-2,2-dichloroethanestarting from perchloroethylene in the presence of catalysts based onCr₂ O₃. See for example Italian patent application No. 24689 A/78 andU.S. Pat. No. 3,755,477.

The process described in U.S. Pat. No. 3,755,477 leads to yields of thementioned product equal to about 20% and it cannot be utilized on acommercial scale because of the too high amount of by-products.

An alternative process (U.S. Pat. No. 4,145,368 and U.S. Pat. No.4,192,322) for preparing the compound of the invention comprisesreacting 1,1,1-trifluoro-2-chloroethane with chlorine. The yields of thecompound of the invention are very low. However to increase the usefulproduct yields, it is possible, according to the above-cited patent, toreact the obtained reaction mixture with further starting product1,1,1-trifluoro-2-chloroethane in the presence of catalysts such as Cr₂O₃, oxyfluorides or activated carbon.

Also when using this method, the yields of useful product1,1,1-trifluoro-2,2-dichloroethane are of the order of 14%.

This process is not utilizable on an industrial scale as it requires tworeaction steps plus a third steps which is necessary to prepare thestarting produce. Furthermore, the contact time of the reagents used inthe step where the catalyst based on Cr₂ O₃ or the ones cited above isof the order of 90 seconds. These times are too long for an industrialprocess in the gas phase, because it requires too large reactors.

Processes for the liquid-phase-hydrofluorination of halogenated olefinsfor preparing chlorofluorohydrocabons are well known in the art, suchprocesses using, as catalysts, for example TaF₅, BF₃, SbCl₃ F₂.

When perchloroethylene is utilized as a starting product, it is notpossible to obtain the product of the invention.

This product is obtainable with very low yields, of about 10%, bypreviously reacting perchloroethylene with HF and by subsequenthydrofluorination in the presence of TaF₅. See, for example, JournalFluorine Chemistry, 13 (1979), 7-18, "Chemistry of Hydrogen Fluoride v.Catalysts for Reaction of HF with Halogenated Olefins", A. E. Feiring.

In the art there are known many modifications of the various types offluorination catalysts which are utilized for preparingperhalo-compounds of chlorofluorohydrocarbons.

There are known, in fact, fluorination catalysts based on chrome oxides,oxyfluorides, fluorides of copper, iron, nickel, manganese, cobaltfluorides, etc. carried on Al₂ O₃, AlF₃, activated carbon, CaF₂.

However it is well known that carriers different from the fluorinatedones, in the presence of HF tend to give the corresponding fluorinatedcarriers. Therefore, in practice, the reaction which leads tofluorocarbons is carried out in the presence of a fluorinated carrier.

However, the product of the invention is not exemplified in any patentsexcept the ones mentioned above.

U.S. Pat. No. 3,258,500 describes various fluorination catalysts, amongwhich is Cr₂ O₃. The 1,1,1-trifluoro-2,2-dichloroethane yields are ofabout 16% if it is operated at about 300° C. and they sink to about 3.5%if it is operated at 400° C. In said patent, column 7, lines 30-52, itis specified that it is essential, when using these catalysts, tooperate at exactly defined temperatures in to obtain good conversions tothe desired useful product. As mentioned above, the best mode of thispatent for the product 1,1,1-trifluoro-2,2-dichloroethane indicates 16%as the best result.

Furthermore, this patent indicates, as a possible alternative, thepossibility of supporting chrome oxide on various inert supports; forexample Al₂ O₃ (column 6, lines 23-54). Nevertheless the results soobtained are of little interest as the yields decrease,

The process according to said patent is in any case of low industrialvalue because the by-product amount is too high.

DETAILED DESCRIPTION OF THE INVENTION

It has surprisingly been found that it is possible to prepare1,1,1-trifluoro-2,2-dicloroethane by a process which is readilypracticable on an industrial scale, if perchloroethylene is used as astarting product.

Thus, the object of the present invention is a process for preparing1,1,1-trifluoro-2,2-dichloroethane, which comprises reactingperchloroethylene with HF in the gas phase in the presence of catalystswhich comprise Cr₂ O₃ supported on AlF₃, in the gamma and/or beta form.

Generally, the amount of Cr₂ O₃ ranges from 1 to 15% by weight,calculated as Cr on the catalyst. The percentage of Cr₂ O₁ is a functionof the surface area of AlF₃ in the gamma form.

Carriers having a high surface area, of the order of 25-30 m² /g, aregenerally preferred. In his case it is possible to use Cr₂ O₃ amountsalso lower than 5%.

If the surface area is lower, higher Cr₂ O₃ amounts are generallyutilized.

The carrier can be in the form of powders having particle size generallyranging from 20 to 200 micron. If necessary, it can be also in the formof pellets.

AlF₃ may contain, besides the gamma and/or beta form, also the deltaform, generally also in percentages up to 30% by weight.

AlF₃ in the alpha form can be present too, although it should hepreferably limited because it was observed that this form is littleactive.

The catalyst of the invention can be prepared in various manners, one ofthe preferred methods being the following: the AlF₃ carrier in thecrystallographic forms is wet or dry impregnated, according to atechnique known in the art, with a solution of a soluble trivalentchromium salt, for example CrCl₃.6H₂ O.

The catalyst is then dried to remove the water contained therein. Thenit is charged into a reactor and subjected to an activation treatmentwith air or nitrogen either or not in the presence of steam.

The activation treatment is generally carried out at temperatures from200° to 600° C., preferably from 350° C. to 500° C., to convert chrometo the oxide form.

The above-mentioned allotropic structures of AlF₃ are known and arecharacterized by the X-ray diffraction pattern, as is reported inJ.C.P.D.S. 1981 and in French patent No. 1,383,927 to Du Pont.

The above-considered gamma_(c), delta_(c) and beta_(c) phases are theones described in French patent No. 1,383,927 by J. Christoph and J.Teufer. The alpha phase is described in Anal. Chem. 29, 984 (1957).

After a prolonged use, the catalyst activity can he restored by atreatment with air at high temperatures (from 350° to 500° C.), however,these regenerations are to be conducted cautiously as they can impairthe catalyst life. It was observed, for example, that the heattreatments can promote the irreversible conversion of the aluminiumtrifluoride active phases to the alpha-AlF₃ inactive phase.

The molar ratio between reagents HF and C₂ Cl₄ is at least of 3:1, inparticular of 5:1. It was ascertained that lower molar ratios lead tolow conversions of C₂ Cl₄ and,in any case shorten the catalyst life asthey favour the deposition of carbon and organic pitches onto thecatalyst surfaces, thereby reducing the catalytic activity.

The reaction temperature ranges From 250° to 500° C. and preferably from300° to 400° C.

The contact time between reagents and catalyst mass ranges from 1 second30 seconds, preferably from 3 to 15 seconds.

The 1,1,1-trifluoro-2,2 -dichloroethane yields obtained through theprocess of the invention are of the order of 15-20% by moles if it isoperated under the above-mentioned conditions.

However, contrary to expectation, in the process of the invention theother reaction products consist, besides for the most part of theunreacted starting product of partially fluorinated intermediates, whileonly about 20% by moles consists of highly fluorinated low-boilingproducts.

By simple stripping it is possible to separate the unreactedperchloroethylene and the partially fluorinated intermediates and torecycle them again to obtain the product of the invention. The feedingmixture in the recycle is added with fresh perchloroethylene.

In this manner, the yields of 1,1,1trifluoro-2,2-dichloroethane productcan reach 90% by moles.

This is a very important advantage of the process of the presentinvention with respect to the above-cited known processes for preparing1,1,1-trifluoro-2,2-dichloroethane. As in the above-illustrated patents,the reaction by-products were so highly fluorinated that they could notbe recycled.

For the purpose of a better comprehension of the present invention it istherefore useful to consider the net yield of1,1,1-trifluoro-2,2-dichloroethane, intermediates and by-products.

As regards this invention the term "net yield" means the followingexpression: ##EQU1##

In the present invention, the net yield of by-products is very low,generally it is of 10%.

The utilization of the compound forming the object of the invention arewell known in the art. In particular it is utilized as a fluid foraerosol or as a propellant.

EXAMPLES

The following examples are given merely to illustrate this invention,without being however a limitation thereof.

Example 1

A) 240 g of aluminium trifluoride, consisting for 30% of delta-AlF₃, for60% of gamma-AlF₃ and for the remaining 10% of beta-AlF₃ and alpha-AlF₃,were impregnated with a solution prepared by dissolving 52.3 g ofCrCl₃.6H₂ O in 58 ml of distilled water. Aluminium trifluoride wascomposed of particles having diameters ranging from 20 to 200 micron,the average diameter being of 80 micron. Aluminium trifluoride wasimpregnated by dropping of the Cr₂ Cl₃.6H₂ O under stirring.Subsequently the catalyst was partially dried in oven at 110° C. for 1.5hours, whereafter it was placed into a tubular reactor made of Inconel600, having an inside diameter of 5 cm, a height of 8O cm and beingequipped on the bottom with a porous septum made of sinterized Inconelfor uniformly distributing the gases entering from the bottom and forsupporting the inactive catalytic bed. The thermo-couples for thetemperature measurements were placed in a sheath arranges in the middleof the reactor.

The catalyst placed in the abovesaid reactor was heated up to 200° C. ina nitrogen flow of 100 l/h. The N₂ flow was stopped and 100 l/h of airand 80 l/h of HF were sent to the reactor after having been reciprocallymixed in the preheater arranged upstream of the reactor. Heating wasresumed in an air and HF stream until a temperature of 400° C. wasreached. This temperature was maintained for 2 hours, whereafter thecatalyst was cooled in a N₂ flow.

B) Using the catalyst so prepared and the same apparatus, 0.855 moles/hof C₂ Cl₄ and 3.542 moles/h of HF were sent to the reactor. The reactiontemperature was of 360° C. and the pressure was slightly higher than theatmospheric pressure. The contact time-was of 5 seconds calculated asthe ratio between non-fluidized catalyst volume and volumetric flow ofthe reagents fed at the reaction temperature and pressure. The gasesoutflowing from the reactor were drawn for 1 hour. After absorption ofHCl and HF in water and after washing of the reaction product with anaqueous solution of NaOH, 141 g of product were recovered, the molarcomposition of which being as follows:

    ______________________________________                                        CF.sub.3 CHClF        1.2%                                                    CF.sub.3 --CHCl.sub.2 5.1%                                                    CCl.sub.2 ═CClF + CClF.sub.2 --CHCl.sub.2                                                       5.0%                                                    C.sub.2 Cl.sub.4      88.0%                                                   ______________________________________                                    

The conversion of C₂ Cl₄ was of 12%, while the net yield of CF₃ --CHCl₂was of 42.9% and the net yield of by-products was of 10%.

Example 1A (comparative test)

Into the apparatus of example 1 there were charged 345 g of thealuminium trifluoride used for preparing the catalyst of example 1. At areaction temperature of 360° C. and at a pressure slightly higher thanthe atmospheric pressure, 0.386 moles/h of C₂ Cl₄ and 3.44 moles/h of HFwere fed. After a process analogous with the one described in example 2,147 g of a reaction product having the following molar composition wererecovered:

    ______________________________________                                        CF.sub.3 --CHCl.sub.2 traces                                                  CCl.sub.2 ═CClF + CClF.sub.2 --CHCl.sub.2                                                        1.1%                                                   C.sub.2 Cl.sub.4      98.5%                                                   ______________________________________                                    

Therefore, aluminium trifluoride as such is not suitable for theproduction of CF₃ --CHCl₂.

Example 2

A) 340 g of an aluminium trifluoride essentially consisting ofgamma-AlF₃ having a surface area of 29 m² /g was impregnated with asolution obtained by dissolving 52.3 g of CrCl₃.6H₂ O in 58 ml ofdistilled water. The impregnation and the drying processes were the sameas in example 1. The dried catalyst was charged into the reactor ofexample 1 and was heated up to 450° C. with air at a flow rate of 100l/h. It was maintained at this temperature until only traces of chlorideions were present in the washing solution of the air leaving thereactor. Subsequently it was cooled with nitrogen. The Cr amountreferred to the catalyst was 3% by weight.

B) The catalyst of example 2A (345 g) was charged into the apparatus ofexample 1. At a reaction temperature of 360° C. and at a pressureslightly higher than the atmospheric pressure, 0.925 moles/h of C₂ Cl₄and 3.755 moles/h of HF were fed. In one hour there were collected 148 gof a reaction product, the molar composition of which was the following:

    ______________________________________                                        CF.sub.3 --CHClF        9%                                                    CF.sub.3 --CHCl.sub.2 15.8%                                                   CCl.sub.2 ═CClF + CClF.sub.2 --CHCl.sub.2                                                        5.7%                                                   C.sub.2 Cl.sub.4      64.0%                                                   ______________________________________                                    

The C₂ Cl₄ conversion was of 36%. The CF₃ CHCl₂ net yield was of 44%,the by-products net yield was of 25%.

Example 3

Using he same catalyst of example 2, the same apparatus of example 1, areaction temperature of 340° C. and a pressure slightly higher than theatmospheric pressure. 0.949 moles/h of C₂ Cl₄ and 9.725 moles/h of HFwere fed. Drawing was carried out for an hours, thereby collecting 153 gof a reaction product having he following molar composition:

    ______________________________________                                        CF.sub.3 --CHClF       4.8%                                                   CF.sub.3 --CHCl.sub.2 14.8%                                                   CCl.sub.2 ═CClF + CClF.sub.2 --CHCl.sub.2                                                        7.4%                                                   C.sub.2 Cl.sub.4      71.0%                                                   ______________________________________                                    

The C₂ Cl₄ conversion was of 29%, the ClF₃ CHCl₂ net yield was of 51%and the by-products net yield was of 16%.

Example 4

A) 340 g of an aluminium trifluride containing 80% of gamma-AlF₃ havinga surface area of 18 m² /g was impregnated a first time with a solutionobtained by dissolving 52.3 g of CrCl₃.6H₂ O in 58 ml of distilledwater. The impregnation and drying process was the same as in example 1.After drying, the catalyst was impregnated a second time with the sameamount of chromic solution having the same concentration, until a chromecontent of 6% by weight was obtained.

The catalyst was then dried again, was charged into the reactor ofexample 1 and was treated with a nitrogen flow (100 l/h) saturated withsteam at 40°/50° C. The treatment was carried out at 360° C. until onlytraces of chloride ions were present in the nitrogen washing solutionleaving the reactor. Subsequently it was dried with dry nitrogen.

B) The catalyst of example 4A (345 g) was placed into the paratus ofexample 1. At a reaction temperature of 300° C. and at a pressureslightly higher than the atmospheric pressure there were fed 0.801moles/h of C₂ Cl₄ and 4,171 moles/h of HF. After a 1-hour drawing therewere collected 130 g of a reaction product, the molar composition ofwhich was as follows:

    ______________________________________                                        CF.sub.3 --CHClF      2.2%                                                    CF.sub.3 --CHCl.sub.2 11.2%                                                   CCl.sub.2 ═CClF + CClF.sub.2 --CHCl.sub.2                                                       8.1%                                                    C.sub.2 Cl.sub.4      76.7%                                                   ______________________________________                                    

The conversion of C₂ CL₄ was of 23.3%. The CF₃ CHCL₄ net yield was of48.1% and the net yield of by-products was 9.4%.

Example 5(Comparative Test)

A) To a solution of 10 kg of dodecahydrated chromic potassium alum [KCr(SO₄)₂.12H₂ O] in 71.5 liters of water there was added, at roomtemperature and under stirring, an aqeous solution of ammoniumhydroxide, containing about 10% by weight of NH₃, until the pH reached avalue of 8.8. The hydrated chrome oxide suspension was further stirredfor about 30 minutes a room temperature, taking care that the pH shouldremain between 8.8 and 9.0 by adding, if necessary, further amounts ofNH₄ OH.

The suspension was then diluted with deonized water till bringing thevolume to about 160 liters, then it was allowed to decant for 24 hours,optionally accelerating decantation by means of a flocculating agent(for example it is possible to use from 30 to 40 ppm of ECOCLAR 2001calculated on the slurry).

The highest possible amount of aqueous phase was then syphoned off andthe operation was repeated (dilution with washing effect) further threetimes. After filtration, the hydrated chrome oxide cake was suspended inhot deionized water (85°-90° C., 1,750 grams containing 15% of solidproduct suspended in three liters of water). Hot washing was repeatedseveral times until the sulphate ions (SO₄ ⁻) concentration was lowerthan 0.4% by weight referred to the calcined dry product. A last, thehydrated chrome oxide cake was suspended again in three liters ofacetone at room temperature, thereby obtaining, by filtration, ahydrated chrome oxide, which was activated by calcination in a mufflefurnace according to the following schedule:

5 hours at 100° C.

2 hours at 400° C.

from 4 to 5 hours at a temperature between 500° and 550° C.

Obtained were dark-green pellets having a content of SO₄ ⁻ ions lowerthan 0.04% by weight and a specific surface area of about 88 m² /g.

B) Into the apparatus of example 1 there were charged 460 g of thecatalyst of example 5A in pellets, and, at a reaction temperature of320° C. and at a pressure slightly higher than the atmospheric pressure,1.163 moles/h of C₂ Cl₄ and 4.341 moles/h of HF were fed. After a 1-hourdrawing, 143.4 g of a reaction product having the following molarcomposition were recovered:

    ______________________________________                                        CF.sub.3 CHF.sub.2      10%                                                   CF.sub.3 CHClF         6,1%                                                   CF.sub.3 CCl.sub.2 F   4,6%                                                   CF.sub.3 CH.sub.2 Cl  11,2%                                                   CF.sub.3 CCl.sub.2 H  19,9%                                                   CCl.sub.2 ═CClF + CClF.sub.2 --CHCl.sub.2                                                         2%                                                    C.sub.2 Cl.sub.4      32,1%                                                   ______________________________________                                    

The C₂ Cl₄ conversion was of 66.9%, the net yield of CF₃ --CHCl₂ was of29.7% and the non-recyclable by-products reached 67%.

What we claim is:
 1. A continuous process for preparing1,1,1-trifluoro-2,2-dichloroethane and1,1,1,2-tetrfluoro-2-chloroethane, which comprises reactingperchloroethylene with HF in the gas phase in the presence of a catalystcomprising Cr₂ O₃ carried on AlF₃, without Al₂ O₃, in the gamma and/orbeta form.
 2. The process according to claim 1 , wherein the Cr₂ O₃amount ranges from 1 to 15% by weight calculated as chrome on thecatalyst.
 3. The process according to claim 1, wherein the surface areaof AlF₃ ranges from 15 to 30 m² /g.
 4. The process according to claim 1,wherein AlF₃ is in the form of powders having particle size ranging from20 to 200 microns.
 5. The process according to claim 1, characterizedfurthermore in that the AlF₃ carried can contain also the delta phase upto amounts of 30% by weight.
 6. Process according to claim 1 whereinsaid catalyst is prepared by the steps of:a) impregnating AlF₃ with asolution of a soluble chrome salt; b) drying the catalyst; c) activatingthe catalyst with air and nitrogen, at temperatures ranging from 200° C.to 600° C.
 7. Process according to claim 6, wherein the activation stepis conducted in the presence of steam.
 8. The process according to claim6, wherein the activation temperature ranges from 330° to 500° C.
 9. Theprocess according to claim 1, characterized furthermore in that thereaction temperature ranges from 300° C. to 400° C.
 10. The processaccording to claim 1, characterized furthermore in that the contact timebetween reagents and catalytic mass ranges from 1 second to 30 seconds.11. The process according to claim 1, characterized furthermore in thatthe molar ratio between reagents HF and C₂ Cl₄ is of at least 3:1.